Control system for operating automotive vehicle components

ABSTRACT

There is disclosed a control system for operating automotive vehicle components. The control system typically includes at least a control module programmed with instructions for controlling a heater, a ventilator or both.

CLAIM OF BENEFIT OF FILING DATE

The present application is a continuation of and claims benefit toapplication Ser. No. 11/842,425 filed Aug. 21, 2007, which is acontinuation of and claims benefit to application Ser. No. 10/946,218,filed on Sep. 21, 2004, now U.S. Pat. No. 7,274,007, issued Sep. 25,2007 which is and claims benefit to a non-provisional of applicationSer. No. 60/505,983 filed on Sep. 25, 2003, the contents of which arehereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to a control system foroperating automotive vehicle components such as seat comfort components,instrument panel components or the like.

BACKGROUND OF THE INVENTION

For many years, the automotive industry has been designing controlmodules for operating automotive vehicle components. As examples,industry has designed control modules for operating automotive vehiclecomponents such as seat comfort systems (e.g., heaters, ventilators,lumbar support systems, combinations thereof or the like), steeringwheel heaters, ventilating and air conditioning systems (HVAC) systems,safety features or the like. In the interest of continuing suchinnovation, the present invention provides a control module, which maybe suitable for various applications, but which has found particularutility in operating components of automotive vehicles.

SUMMARY OF THE INVENTION

A controller for controlling one or more components of an automotivevehicle is disclosed. The controller includes at least one controlmodule in signaling communication with a energy source, a sensor, apower stage and a switch wherein the energy source provides power to aheater as dictated by the power stage. The sensor senses a temperatureassociated with the heater and the switch turns the heater on and off.The control module includes programming for comparing representativevalues originating from the sensor to a set of n set point values (V₁ .. . V_(n)) wherein the representative values are representative oftemperatures (T_(s)) sensed by the temperature sensor, the n set-pointvalues are representative of n predetermined temperatures (T₁ . . .T_(n)) and n is a whole number greater than 1. The module also includesprogramming for allowing n different amounts of energy (E₁ . . . E_(n))to be applied to the heater depending upon the representative values.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claimsand drawings, of which the following is a brief description:

FIG. 1 is a schematic diagram of a heater system employing a controlmodule according to an aspect of the present invention;

FIG. 2 illustrates graphs useful for understanding the operation of theheater system of FIG. 1; and

FIG. 3 also illustrates a graph useful for understanding the operationof the heater system of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is predicated upon providing a control system foroperating components of an automotive vehicle. Generally, it iscontemplated that the control system may be employed for operating mostany components of the automotive vehicle. Moreover, it is contemplatedthat the control system may include a single control module, multiplecontrol modules or a universal control module that integrates multiplecontrol modules.

Preferably, the control system includes at least one control moduleuseful for operating vehicle comfort systems including, but not limitedto, seat and steering wheel heaters, seat ventilation systems, lumbarsupport systems, combinations thereof or the like. According to oneaspect of the invention, a control module is provided for operating aheater of a steering handle (e.g., a steering wheel), a heater of avehicle seat, a ventilation system of the vehicle seat or a combinationthereof. An exemplary heater, ventilation system or combination thereoftypically includes one or more conductors, one or more air movers (e.g.,blowers) or a combination thereof in signaling communication with one ormore control modules and one or more temperature sensors in signalingcommunication with the one or more control modules.

One example of a suitable handle or steering wheel heater is disclosedin U.S. Pat. No. 6,727,467, which is incorporated herein by referencefor all purposes. One example of an integrated seat heater and seatventilation system is disclosed in U.S. patent application Ser. No.10/434,890, filed May 9, 2003, titled “Automotive Vehicle Seat Insert”,which is hereby incorporated herein by reference for all purposes.

Referring to FIG. 1, there is illustrated an exemplary control system inaccordance with an aspect of the present invention. As can be seen, thesystem includes a control module 10 in signaling communication with oneor more of a heater 12 (e.g., a steering wheel or seat heater), atemperature sensor 14, a power stage 16 and a switch 18, whichpreferably includes a light emitting diode (LED) 20, each of which isshown as blocks in the block diagram of FIG. 1. It should be understoodthat the circuits shown are exemplary and it is contemplated that othercircuits may be employed within the scope of the present invention.

The heater 12 is preferably a resistive heater comprised of a pluralityof conductors that act as one or more resistors 26, which may beconfigured in parallel, in series or otherwise. As shown, the heater 12is in electrical communication with an energy source 28 (e.g., anautomotive vehicle battery) via an electrical connection 30 (e.g., awire or bus) and the power stage 16 is located along the electricalconnection 30 for dictating amounts of energy provided by the energysource 28 delivers to the heater 12.

Typically, the heater 12 can be turned on by operating the switch 18(e.g., a momentary switch) from an “off” configuration to an “on”configuration such that the switch 18 signals the control module 10 toallow the energy source 28 to deliver power (e.g., electrical energy) tothe heater 12. In the embodiment shown, the control module 10 includesinstructions for signaling the power stage 16 to allow an amount ofenergy (e.g., a percentage of a full voltage of the energy source 28) tobe delivered to the heater 12.

In one embodiment, the control module 10 is programmed with instructionsto apply an amount of energy to the heater 12 based upon a temperaturesensed by the temperature sensor 14. Thus, in one embodiment, thecontrol module 10 includes instructions for applying at least threedifferent amounts (e.g., percentages such 0%, 20% or 100% of fullenergy) of energy to the heater if temperatures sensed are above orbelow at least three different predetermined temperatures.

In a preferred embodiment, a number (n) of predetermined temperatures(T₁, T₂ . . . T_(n)) are selected wherein (n) is any whole numbergreater than two. T_(r), is preferably the highest of the predeterminedtemperatures and is also preferably the desired temperature for theheater 12. Moreover, the temperature T_(n-1) to T₁ preferably becomeprogressively lower. Thus, for example, (n) could be equal to 7 and thefollowing values may be chosen: T_(n)=30° C.; T_(n-1)=28° C.;T_(n-2)=26° C.; T_(n-3)=24° C.; T₁₋₄=22° C.; T_(n-5)=20° C.; T_(n-6)=18°C. Typically n is at least three, more typically at least five and evenmore typically at least seven.

In operation, the temperature sensor 14 senses a temperature associatedwith (i.e., a temperature at or adjacent) the heater 12. Thereafter, thetemperature sensor 14 sends a signal to the control module 10 indicativeor representative of the temperature sensed. For example, for aresistance based temperature sensor, a voltage is typically transmittedto the control module 10 wherein the voltage is representative of thetemperature sensed. In such an embodiment, each predeterminedtemperature T₁ . . . T_(n) will respectively be associated with apredetermined voltage V₁ . . . V_(n) from the temperature sensor 14 andthe predetermined voltages typically decline (e.g., by lowering DCvoltage, decreasing duty cycle or the like) as the predeterminedtemperatures become higher. It should be understood that suchtemperature sensing is typically happening continuously or atintermittent time periods.

In the preferred embodiment, the control module 10 is programmed withinstructions for commanding the power stage 16 to allow (n) differentamounts of energy (E₁ . . . E_(n)) to be delivered to the heater 12depending upon the sensed temperature T_(s) by the temperature sensor14. In the embodiment, the different amounts of energy (E₁ . . . E_(n))are produced by differing the amount of time for which a single voltageis produced during a time period (e.g., a cycle) or by differingvoltages provided to the heater during different time periods or may beotherwise provided as well. Preferably, the different amounts of energy(E₁ . . . E_(n)) respectively inversely correspond to the predeterminedtemperatures (T₁ . . . T_(n)) such that higher predeterminedtemperatures correspond to lower amounts of energy.

The control module 10 is also programmed with a set of instructions tocompare a value representative of the sensed temperature T_(s) withset-point values (e.g., the voltages V₁ . . . V_(n)) that arerepresentative of the predetermined temperatures (T₁ . . . T_(n)) todetermine the highest temperature of the predetermined temperatures (T₁. . . T_(n)) that T_(s) is equal to or below. In turn, the controlmodule 10 commands the power stage 16 to allow one of the differentamounts of energy (E₁ . . . E_(n)) corresponding to the highesttemperature of the predetermined temperatures (T₁ . . . T_(n)) thatT_(s) is equal to or below. Moreover, if the sensed temperature T_(s) isequal to or above T_(n) (i.e., the highest predetermined temperature)then E_(n) (i.e., the lowest or zero amount of energy) is applied to theheater 12.

Accordingly, the table below provides an example of predeterminedamounts of energy produced for voltages that are provided by atemperature sensor based upon sensed temperatures:

Pre- determined amounts of Predetermined Corresponding CorrespondingEnergy Temperatures Resistances Voltages (% of (° C.) (Ohms) (Volts)duty cycle) 25 R ≦ 6610 V ≦ 1.529 0 23 6610 ≦ R ≦ 6733 1.529 ≦ V ≦ 1.54910 21 6733 ≦ R ≦ 6857 1.549 ≦ V ≦ 1.569 20 19 6857 ≦ R ≦ 6983 1.569 ≦ V≦ 1.588 30 17 6983 ≦ R ≦ 7110 1.588 ≦ V ≦ 1.608 40 15 7110 ≦ R ≦ 72381.608 ≦ V ≦ 1.627 50 13 7238 ≦ R ≦ 7368 1.627 ≦ V ≦ 1.647 60 11 7368 ≦ R≦ 7633 1.647 ≦ V ≦ 1.686 70 9 7633 ≦ R ≦ 7904 1.686 ≦ V ≦ 1.725 80 77904 ≦ R ≦ 8182 1.725 ≦ V ≦ 1.765 90 5 8182 ≦ R 1.765 ≦ V 100

Thus, instructions for the controller based upon the above table may bea set of conditions as follows:

If V ≦ 1.529 then E = 0% If 1.549 ≦ V ≦ 1.529 then E = 10% If 1.569 ≦ V≦ 1.549 then E = 20% If 1.588 ≦ V ≦ 1.569 then E = 30% If 1.608 ≦ V ≦1.588 then E = 40% If 1.627 ≦ V ≦ 1.608 then E = 50% If 1.647 ≦ V ≦1.627 then E = 60% If 1.686 ≦ V ≦ 1.647 then E = 70% If 1.725 ≦ V ≦1.686 then E = 80% If 1.765 ≦ V ≦ 1.725 then E = 90% If 1.784 ≦ V ≦1.765 then E = 100%

It should be recognized that these instructions may be programmed intothe control module in a variety of ways and that various differentinstructions may provide the various energy outputs for the varioustemperature ranges.

Advantageously, the control module programmed with the instructionsallows the heater 12 to reach its desired temperature (e.g., T_(n))while minimizing the amount by which the heater temperature will exceedthe desired temperature. As shown in Graph I of FIG. 3, a conventionalheater can significantly exceed the desired temperature and oscillateabout the desired temperature. However, as shown in Graph II of FIG. 3,a heater according to the present invention can reach the desiredtemperature without significantly exceeding the desired temperature andwithout significantly oscillating about the desired temperature.

According to another aspect of the invention, the control module 10 isprogrammed for preventing underheating, overheating or both.Accordingly, the control module 10 is programmed with data, whichcorrelates a value representative of the temperature sensed by thetemperature sensor 14 to an amount of energy provided to the heater 12.Such data is typically acquired by system modeling (i.e., testing theheater to determine temperatures or temperature changes that are sensedfor a range of energies or a range of energy changes that are applied tothe heater). As such, the data may be supplied as data points, asmathematical functions or the like.

For preventing overheating or underheating, the temperature sensor 14provides values to the control module 10 representative of thetemperatures being sensed by the sensor 14 over time. Theserepresentative values are matched with amounts of energy that thecontrol module 10 is instructing the power stage 16 to deliver to theheater 12 over time. In turn, the control module 10 is programmed tocompare the representative values and corresponding amounts of energy tothe programmed data to assure that the energy being applied to theheater 12 is producing a temperature or temperature change commensuratewith an expected temperature change provided by the data.

If the temperatures are commensurate with the energies being applied,the control module 10 typically continues to control the heater 12 inits normal manner. However, if the temperatures are not commensuratewith the energies, the control module 10 typically shuts the heater 12down and optionally instructs that LED 20 of the switch 18 to flash.Referring to FIG. 4, there is illustrated a graph plotting temperaturesensor values (shown as resistances (R_(ntc))) a versus time (t). In thegraph, two scenarios are modeled as mathematical functions, which arerepresented by data curves 40, 44. Preferably, the data curves 40, 44are modeled using empirical data from the heater 12. In the embodimentshown, one data curve 40 models the expected temperature sensor valueswith respect to time for a scenario in which the power source 28delivers a minimum acceptable amount of energy (e.g., 8.5 volts) to theheater 12 and the heater 12 does not exhibit a fault condition (e.g., acondition that would substantially change the heat output of theheater). The other data curve 44 models the expected temperature sensorvalues with respect to time for a scenario in which the power source 28delivers a maximum acceptable amount of energy (e.g., 16.5 volts) to theheater 12 and the heater 12 does not exhibit a fault condition.

Once these scenarios are modeled, two fault curves 50, 54 areestablished as mathematical functions based upon the data curves 40, 44.Preferably, the fault curves 50, 54 are established to be within percenttolerances (e.g., 30% or less) of the data curves 40, 44. Thus, onefault curve 50 is modeled as having temperature sensor values thatchange slower (e.g., at the maximum percent tolerance slower) than thedata curve 40 for which the minimum acceptable amount of energy isapplied to the heater 12. The other fault curve 54 is modeled as havingtemperature sensor values that change faster (e.g., at the maximumpercent tolerance faster) than the data curve 44 for which the maximumacceptable amount of energy is applied to the heater 12.

Advantageously, the fault curves 50, 54 can be programmed into thecontrol module 10 such that the actual changes of temperature sensorvalues can be compared to the fault curves 50, 54 to detect whether afault condition is present for the heater 12. For example, the controlmodule 10 may be programmed to shut down the heater 12 if the heater 12is exhibiting changes in temperature sensor values that are slower thanor outside the fault curve 50, which is based upon the minimumacceptable energy level being applied to the heater 12 (e.g., where anunderheating fault condition is present such as that represented by areal data curve 56). Alternatively or additionally, the control module10 may be programmed to shut down the heater 12 if the heater module 10is exhibiting changes in temperature sensor values that are faster thanor outside the fault curve 54 that is based upon the maximum acceptableenergy level being applied to the heater 12 (e.g., where an overheatingfault condition is present such as that represented by a real data curve58). Moreover, whenever a fault condition is detected, the controlmodule 10 may command the LED 18 to flash to indicate such fault.

It should be recognized that it may be desirable for the control moduleto be programmed to shutdown the heater if the current flowing throughthe heater is to high (i.e., an overcurrent condition) or too low (i.e.,an undercurrent condition). In such an embodiment, the control moduletypically continuously monitors the current flowing through the heaterand if that current falls below a lower current threshold or rises abovean upper current threshold, the control module commands the heater toshutdown. In one preferred embodiment, the control module alsocontinuously monitors the voltage being delivered to the heater and, inturn, the control module will adjust the upper and lower currentthresholds based upon the voltage measurements (i.e., the thresholdswill be raised or lowered in correspondence respectively with the up anddown fluctuations of the voltage measurements that can typically beexperienced from the energy source). In this preferred embodiment, thecontrol module may also be programmed to shut down the heater if voltagemeasurements go respectively above or below predetermined upper andlower voltage thresholds (e.g., above 16.5 volts or below 9.0 volts).

According to another aspect of the invention, the system includes aventilation system and a heater. In such a system, the control module 10is typically additionally in signaling communication with an air mover34 (e.g., a blower) configure for moving air that is adjacent trim coveror passenger of a seat. Thus, the control module is typically programmedwith instructions for operating both the air mover 34 and the heater 12.Such programming may include instructions for turning the heater 12 andthe air mover 34 on and off and such programming may includeinstructions for operating the heater 12, the air mover 34 or both at arange of different output levels.

According to a preferred embodiment, the control module 10 is programmedwith instructions for providing remedial measures if excessiveventilation (e.g., overcooling) and/or excessive heating (e.g.,overheating) is detected. The remedial measures can include turning theair mover 34 on in the event that the temperature sensor 14 senses,respectively, a temperature in excess of a predetermined upper limittemperature and turning the heater 12 on in the event that thetemperature sensor 14 senses a temperature below a predetermined lowerlimit temperature.

In a highly preferred embodiment, the control module 10 is programmedwith instructions for, during operation of the heater 12, comparing arepresentative value of a temperature sensed by the temperature sensor14 to a first set-point value representing a first upper limittemperature. Based upon the comparison, if the sensed temperature isgreater than the first upper limit temperature, the control module 10includes instructions for activating the air mover 34 for apredetermined time period, preferably, although not necessarily, whilethe heater 12 remains on.

In the embodiment, the control module 10 is also preferably programmedwith instructions for, during operation of the heater 12 and optionallythe air mover 34 as well, comparing the representative value of thetemperature sensed by the temperature sensor 14 to a second set-pointvalue representing a second upper limit temperature greater than thefirst upper limit temperature. Based upon the comparison, if the sensedtemperature is greater than the second upper limit temperature, thecontrol module 10 includes instructions for turning the heater 12 offand turning the air mover 34 on or allowing the air mover 34 to remainon at least until the sensed temperature falls below the second upperlimit.

In addition or alternatively, the control module 10 is programmed withinstructions for, during operation of the air mover 34, comparing arepresentative value of a temperature sensed by the temperature sensor14 to a first set-point value representing a first lower limittemperature. Based upon the comparison, if the sensed temperature isless than the first lower limit temperature, the control module 10includes instructions for activating the heater 12 for a predeterminedtime period, preferably, although not necessarily, while the air mover34 remains on.

In the embodiment, the control module 10 is also preferably programmedwith instructions for, during operation of the air mover 34 andoptionally the heater 12 as well, comparing the representative value ofthe temperature sensed by the temperature sensor 14 to a secondset-point value representing a second lower limit temperature less thanthe first upper limit temperature. Based upon the comparison, if thesensed temperature is less than the second lower limit temperature, thecontrol module 10 includes instructions for turning the air mover offand turning the heater 12 on or allowing the heater 12 to remain on atleast until the sensed temperature raises above the second lower limit.

The control module may also be programmed with other additional featuresas well. In one embodiment, the control module is programmed to providesubstantially constant energy to the LED such that the light emitted bythe LED is substantially constant during operation thereof. In such anembodiment, the control module is programmed to deliver differentpercentages of energy to the LED depending on the amount of voltagebeing delivered by the energy source or automotive vehicle battery. Inparticular, the control module receives continuous signals indicative ofthe amount of voltage being supplied by the energy source (e.g., thevehicle battery) and, in turn, the control module adjusts the percentageof that amount of voltage that is actually delivered to the LED (e.g.,adjusts the percentage of time or number of cycles for which fullvoltage is supplied). Thus, fluctuations in the amount of voltagesupplied by the energy source are accounted for such that the LED canemit a substantially continuous amount of light at least duringoperation.

The control module may also be programmed with an additional shutdownfeature for instances in which a relatively large amount of energy issupplied to the heater for a predetermined amount of time. For example,the control module can be programmed to shut down or stop providingenergy to the heater if the power supply has been providing energy at alevel greater than 80%, more typically greater than 90% and even moretypically about 100% of full energy (i.e., the maximum amount of energytypically supplied to the heater) for a period of time greater thanabout 10 minutes, more typically greater than about 20 minutes and evenmore typically about 30 minutes.

In another embodiment, the control module may be programmed with astart-up feature, which is designed to have the power supply provideenergy to the heater for a predetermined time upon sensing of atemperature below a particular threshold level at initial start up. Forexample, under relatively cold conditions (e.g., temperatures belowabout −20° C. or about −30° C.) it may be possible for the temperaturesensor, particularly at initial start-up of the automotive vehicle, theheater or both, to send a signal indicative of a fault even though theheater may still be operable in its desired ranges. As such, the controlmodule can be programmed to, upon sending of a fault condition or anextremely low temperature at start-up of the heater, signal the powersupply to provide energy at a predetermined level greater than 80% moretypically greater than 90% and even more typically about 100% of fullenergy (i.e., the maximum amount of energy typically supplied to theheater) for a period of time between about 10 seconds and 5 minutes,more typically between about 50 second and 3 minutes and even moretypically between about 80 seconds and 100 seconds. In this manner, thesensed temperatures can be brought into normal readable ranges for thetemperature sensor such that the heater and control module can beginoperating normally. However, if the sensed temperature remains very lowor if the temperature sensor continues to indicate a fault condition,the heater will likely be shut down.

It is also contemplated that the system may include a stuck buttondetection feature, which only allows the heater or ventilator to beactivated when the on/off switch is a button and the button returns toits normal non-depressed position after that button has been depressed.Thus, if the button becomes stuck in a depressed position, the heater,the ventilator or both will not be activated or turned on.

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1. A controller for controlling at least an air mover and a heater of anautomotive vehicle comprising; at least one control module in signalingcommunication with an energy source, a sensor, the air mover, a powerstage and a switch wherein the energy source provides power to theheater as dictated by the power stage, the sensor senses a temperatureassociated with the heater and the switch turns the heater on and offand wherein the control module includes: i. programming for comparingrepresentative values originating from the sensor to a set of n setpoint values (V₁ . . . V_(n)) wherein the representative values arerepresentative of temperatures (T_(s)) sensed by the temperature sensor,the n set-point values are representative of n predeterminedtemperatures (T₁ . . . T_(n)) and n is a whole number greater than 1,wherein n is at least 3 ii. programming for allowing n different amountsof energy (E₁ . . . E_(n)) to be applied to the heater depending uponthe representative value, such different amount be applied during aninitial heat up time period of the heater once the heater is turned on;and iii. programming for providing remedial measures if a relativelyhigh temperature or a relatively low temperature is detected wherein theremedial measures include programming for turning the air mover on inthe event that the temperature sensor senses a temperature in excess ofa predetermined upper limit temperature and programming for turning theheater on in the event that the temperature sensor senses a temperaturebelow a predetermined lower limit temperature.
 2. A controller as inclaim 1 wherein the programming for comparing the representative valuesand the amount of energy being applied to the heater with programmeddata includes establishing a first fault curve and a second fault curvewherein the first fault curve is modeled as having temperature sensorvalues that change slower than expected and the second fault curve ismodeled as having temperature sensor values that change faster thanexpected.
 3. A controller as in claim 1 wherein the switch includes alight emitting diode (LED) and wherein the control module is programmedto provide substantially constant energy to the LED such that the lightemitted by the LED is substantially constant during operation thereof.4. A controller as in claim 1 wherein the control module is programmedwith a start-up feature, which is designed to have the power supplyprovide energy to the heater for a predetermined time upon sensing of atemperature below a particular threshold level at initial start up.
 5. Acontroller as in claim 1 wherein the controller includes a stuck buttonfeature, which only allows the heater or the air mover to be activatedwhen the on/off switch is a button and the button returns to its normalnon-depressed position after that button has been depressed.
 6. Acontroller as in claim 1 wherein the different amounts of energyrespectively correspond to the predetermined temperatures such thathigher predetermined temperatures correspond to lower amounts of energyand wherein the heater is selected from a seat heater or a steeringwheel heater of the automotive vehicle.
 7. The controller as in claim 1,wherein the different amounts of energy are produced by differing theamount of time for which a single voltage is produced during a timeperiod.
 8. The controller as in claim 1, wherein the different amountsof energy are produced by differing voltages provided to the heaterduring different time periods.
 9. The controller as in claim 5, whereinthe sensor is a resistance based temperature sensor.
 10. The controlleras in claim 5, wherein the different amounts of energy (E₁ . . . E_(n))respectively inversely correspond to the predetermined temperatures (T₁. . . T_(n)) so that higher predetermined temperatures correspond tolower amounts of energy.
 11. The controller as in claim 1, wherein theat least one control module is programmed with instructions that allowthe heater to reach a desired temperature while minimizing an amount bywhich a heater temperature will exceed the desired temperature.
 12. Thecontroller as in claim 11, wherein the heater reaches the desiredtemperature without significantly exceeding the desired temperature andwithout significantly oscillating about the desired temperature.
 13. Thecontroller as in claim 1, wherein the control module is programmed withdata, which correlates the representative values of the temperaturesensed by the temperature sensor to an amount of energy provided by theheater.
 14. The controller as in claim 13, wherein the data is suppliedas data points or mathematical functions.
 15. The controller as in claim1, wherein if the temperatures sensed by the temperature sensor are notcommensurate with the amount of energy applied to the heater, thecontrol module shuts the heater down.
 16. The controller as in claim 15,wherein the control module instructs light emitting diode (LED) of theswitch to flash when the control module shuts the heater down.
 17. Thecontroller as in claim 1, wherein the control module is programmed toshut down or stop providing energy to the heater if the energy sourceprovides power to the heater at a level greater than 80% for a period oftime greater than about 20 minutes.
 18. The controller as in claim 16,wherein the control module is programmed to shut down or stop providingenergy to the heater if the energy source provides power to the heaterat a level greater than 90% for a period of time greater than about 10minutes.
 19. The controller as in claim 4, wherein the control module isprogrammed to send a signal to the energy source to provide power to theheater at a predetermined level greater than 80 percent for a period oftime between about 10 seconds and 5 minutes when the sensor, senses thetemperature below the threshold level at initial start-up.
 20. Thecontroller as in claim 19, wherein the control module continuouslymonitors the amount of energy being applied to the heater.